Terex RL4 User manual

Operator's Manual

RL4

ANSI/CSA

North America

South America

Asia

Vertical Mas

t

with

Maintenance

Information

First Edition

Second Printing

Part No. 1266664

Operator's Manual First Edition • Second Printing

RL4 Vertical Mast Part No. 1266664

Front Matter

Important

Read, understand and obey these safety rules and

operating instructions before operating this

machine. Only trained and authorized personnel

shall be permitted to operate this machine. This

manual should be considered a permanent part of

your machine and should remain with the machine

at all times. If you have any questions, contact us.

Contact Us:

Internet: www.terex.com

E-mail: [email protected]

Contents

Introduction ........................................................... 1

Symbol and Hazard Pictorials Definitions ............. 4

General Safety ...................................................... 6

Work Area Safety ................................................ 10

Legend ................................................................ 16

Controls ............................................................... 17

Inspections .......................................................... 21

Operating Instructions ......................................... 32

Transport and Lifting Instructions ....................... 38

Maintenance ....................................................... 40

Specifications ...................................................... 43

Reporting Safety Defects .................................... 44

First Edition: Second Printing, January 2016

"Terex" is a registered trademark of Terex USA, LLC in the

USA and many other countries.

First Edition • Second Printing Operator's Manual

Introduction

Part No. 1266664 RL4 Vertical Mast 1

Introducti on

About this manual

Terex appreciates your choice of our machine for

your application. Our number one priority is user

safety, which is best achieved by our joint efforts.

This book is an operation and daily maintenance

manual for the user or operator of a Terex

machine.

This manual should be considered a permanent

part of your machine and should remain with the

machine at all times. If you have any questions,

contact Terex.

Product Identification

The machine serial number is located on the serial

label.

Intended Use

This machine is intended to be used only to

provide lighting and electrical power to a work site.

Use of this product in any other way is prohibited

and contrary to its intended use.

Bulletin Distribution and

Compliance

Safety of product users is of paramount

importance to Terex. Various bulletins are used by

Terex to communicate important safety and

product information to dealers and machine

owners.

The information contained in the bulletins is tied to

specific machines using the machine model and

serial number.

Distribution of bulletins is based on the most

current owner on record along with their

associated dealer, so it is important to register your

machine and keep your contact information up to

date.

To ensure safety of personnel and the reliable

continued operation of your machine, be sure to

comply with the action indicated in a respective

bulletin.

Operator's Manual First Edition • Second Printing

Introduction

2 RL4 Vertical Mast Part No. 1266664

Contacting the Manufacturer

At times it may be necessary to contact Terex.

When you do, be ready to supply the model

number and serial number of your machine, along

with your name and contact information. At

minimum, Terex should be contacted for:

Accident reporting

Questions regarding product applications and

safety

Standards and regulatory compliance information

Current owner updates, such as changes in

machine ownership or changes in your contact

information. See Transfer of Ownership, below.

Transfer of Machine Ownership

Taking a few minutes to update owner information

will ensure that you receive important safety,

maintenance and operating information that

applies to your machine.

Please register your machine by visiting us on the

web at www.genielift.com or by calling us toll free

at 1-800-536-1800.

Danger

Failure to obey the instructions and

safety rules in this manual will result

in death or serious injury.

Do Not Operate Unless:

 You learn and practice the principles of safe

machine operation contained in this operator’s

manual.

1 Avoid hazardous situations.

Know and understand the safety rules

before going on to the next section.

2 Always perform a pre-operation inspection.

3 Always perform function tests prior to use.

4 Inspect the workplace.

5 Only use the machine as it was intended.

 You read, understand and obey the

manufacturer’s instructions and safety

rules—safety and operator’s manuals and

machine decals.

 You read, understand and obey employer’s

safety rules and worksite regulations.

 You read, understand and obey all applicable

governmental regulations.

 You are properly trained to safely operate the

machine.

First Edition • Second Printing Operator's Manual

Introduction

Part No. 1266664 RL4 Vertical Mast 3

Hazard Classification

Decals on this machine use symbols, color coding

and signal words to identify the following:

Safety alert symbol—used to alert

you to potential personal injury

hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Indicates a hazardous situation

that if not avoided, will result in

death or serious injury.

Indicates a hazardous situation

that if not avoided, could result in

death or serious injury.

Indicates a hazardous situation

that if not avoided, could result in

minor or moderate injury.

Indicates information considered

important, but not hazard related

(e.g. messages related to

property damage)

Safety Sign Maintenance

Replace any missing or damaged safety signs.

Keep operator safety in mind at all times. Use mild

soap and water to clean safety signs. Do not use

solvent-based cleaners because they may damage

the safety sign material.

DANGER

WARNING

CAUTION

NOTICE

Operator's Manual First Edition • Second Printing

Symbol and Hazard Pictorials Definitions

4 RL4 Vertical Mast Part No. 1266664

Symbol and Hazard Pic torials Definiti ons

Read the operator’s

manual

Electrocution hazard Stop engine Earth ground Electrocution hazard

Maintain required

clearance

Explosion / Burn

hazard

Disconnect battery

Read the service

manual

Keep away from

moving parts

Keep away from

moving parts

Explosion / Burn

hazard

Explosion / Burn

hazard

Corrosive acid. Explosion hazard

Do not use high

energy starting aids

on machines

equipped with glow

plugs or grid heater.

No smoking No flame No flame Burn hazard

Stay clear of hot

surfaces and

components

First Edition • Second Printing Operator's Manual

Symbol and Hazard Pictorials Definitions

Part No. 1266664 RL4 Vertical Mast 5

Burn hazard, hot

components

Shattering glass

hazard

Carbon Monoxide

hazard

Do not use light

tower indoors

Wear protective

clothing

Lifting point Tie-down point Tip-over hazard

Deploy outriggers

before raising mast

Tip-over hazard, tow

speed

Keep protective

barriers in place

Electrocution/

entanglement hazard

Electrocution/

entanglement hazard

Flashing beacon

indicates engine may

start at any time

Access by trained

and authorized

personnel only

Operator's Manual First Edition • Second Printing

General Safety

6 RL4 Vertical Mast Part No. 1266664

General Safety

First Edition • Second Printing Operator's Manual

General Safety

Part No. 1266664 RL4 Vertical Mast 7

Operator's Manual First Edition • Second Printing

General Safety

8 RL4 Vertical Mast Part No. 1266664

First Edition • Second Printing Operator's Manual

General Safety

Part No. 1266664 RL4 Vertical Mast 9

Operator's Manual First Edition • Second Printing

Work Area Safety

10 RL4 Vertical Mast Part No. 1266664

Work Area Safety

Electrocution Hazards

This machine is not electrically insulated and will

not provide protection from contact with or

proximity to electrical current.

Before operating the machine, contact the electric

power line owner to disconnect, move, or insulate

power lines.

Obey all local and governmental regulations

regarding required clearance from electrical power

lines. At a minimum, the required clearance

contained in the chart below must be followed.

Line Voltage Required Clearance

0 to 50KV 10 ft 3.05 m

>50 to 200KV 15 ft 4.60 m

>200 to 350KV 20 ft 6.10 m

>350 to 500KV 25 ft 7.62 m

>500 to 750KV 35 ft 10.67 m

>750 to 1000KV 45 ft 13.72 m

over 1000KV see below

For power lines over 1000kV, the minimum

clearance distance must be established by the

utility owner or operator or by a registered

professional engineer who is a qualified person

with respect to electrical power transmission and

distribution.

Allow for mast movement, electrical line sway or

sag, and beware of strong or gusty winds.

Do not operate the machine during lightning or

storms.

Do not use the machine as a ground for welding.

Keep away from the

machine if it contacts

energized power lines.

Personnel must not touch

or operate the machine

until energized power lines

are shut off.

Do not connect wires directly to the generator.

Connect auxiliary equipment only to the power

outlets provided.

Do not perform service or replace the lamps with

the engine/generator running or batteries

connected.

This machine should be grounded in accordance

with all local electrical codes. Consult the local

electrical codes or authority having jurisdiction in

the area where the machine will be used for

specific requirements.

There is a permanent conductor between the

generator (static winding) and the frame.

First Edition • Second Printing Operator's Manual

Work Area Safety

Part No. 1266664 RL4 Vertical Mast 11

Explosion and Fire Hazards

Do not start the engine if you smell or detect liquid

petroleum gas (LPG), gasoline, diesel fuel or other

explosive substances.

Stop engine before adding fuel.

Do not refuel the machine while it

is hot. Allow to cool for several

minutes before refueling.

Do not spill fuel inside the engine

compartment.

Refuel the machine and charge the battery only in

an open, well-ventilated area away from sparks,

flames and lighted tobacco.

Do not operate the machine in hazardous locations

or locations where potentially flammable or

explosive gases or particles may be present.

Do not use high energy

starting aids on machines

equipped with glow plugs or

grid heater.

Tip-over Hazards

Do not raise the mast unless all

outriggers are properly

deployed, the foot pads are in

firm contact with the ground and

the machine is level.

Do not set the machine up on a

surface where it cannot be

leveled using only the leveling

j

acks.

Do not hang objects from the lights or the mast.

Do not use the mast to raise material or personnel.

Do not move the machine unless the mast is

lowered to the stowed position.

Do not raise the mast

when wind speeds may

exceed 60 mph / 97 km/h.

Do not alter or disable

machine components that

in any way affect safety

and stability.

Operator's Manual First Edition • Second Printing

Work Area Safety

12 RL4 Vertical Mast Part No. 1266664

Do not alter or disable machine components that in

any way affect safety and stability.

Do not adjust or stow the outriggers when the mast

is raised.

Be sure the tires are in good condition and the lug

nuts tightened.

Do not place ladders or

scaffolds against any part

of the machine.

Do not use the machine

on a moving or mobile

surface or vehicle.

Crushing Hazard

Do not lower the mast unless

the area below is clear of

personnel and obstructions.

Keep hands and fingers away

from any potential pinch

points.

Collision Hazards

Check the work area for overhead obstructions or

other possible hazards.

Ensure that the collision area around the mast and

light fixtures is clear before rotating the mast.

Stay clear of moving mast.

Always use the light fixture bar rotation lock before

replacing light fixtures.

Burn Hazards

Stay clear of hot components and surfaces.

Allow machine to cool before servicing.

Do not use the machine if the protective barrier on

any of the lamps is broken or punctured. Metal

halide lamps produce shortwave ultra-violet

radiation and can cause serious skin burns or eye

inflammation if the protective barrier is not in place.

Do not touch the lamp fixtures

while they are turned on. Turn the

lamps off and allow them to cool

before touching.

Do not touch hot parts of the

engine or tailpipe, Use protective

gloves when handling hot parts.

First Edition • Second Printing Operator's Manual

Work Area Safety

Part No. 1266664 RL4 Vertical Mast 13

Bodily Injury Hazard

Breathing carbon monoxide can result in death or

serious injury. Do not use the machine indoors.

Use only outside, far from open windows, doors

and vents.

Do not breathe exhaust fumes.

Do not work on this equipment when mentally or

physically fatigued.

Do not work on this equipment when under the

influence of drugs or alcohol.

Stay clear of belts and fan when engine is running.

Do not use where people will remain close to the

lamps for more than a few minutes unless

adequate shielding or other safety precautions are

used.

Do not grasp the cable.

Use proper lifting techniques when lifting and

positioning the tongue of the machine.

Always replace the protective lamp cover after

replacing the lamp bulbs. Keep protective barriers

in place during operation.

Read manuals. If you do not understand the

information in the manuals consult your supervisor,

the owner or the manufacturer.

Fall Hazards

Do not climb or stand on any part of the light tower

during maintenance or operation.

Traffic Hazards

Stand clear of traffic when starting or checking the

unit along the road.

Damaged Machine Hazards

Do not use a damaged or malfunctioning machine.

Do not use a machine with a worn, frayed, kinked

or damaged cable.

Conduct a thorough pre-operation inspection of the

machine and test all functions before each work

shift. Immediately tag and remove from service a

damaged or malfunctioning machine.

Be sure all maintenance has been performed as

specified in this manual and the appropriate Terex

service manual.

Be sure the operator's manual is complete, legible

and in the storage container located on the

machine.

Be sure all decals are in place and legible.

Do not modify or alter the light tower without the

prior written permission of the manufacturer.

Operator's Manual First Edition • Second Printing

Work Area Safety

14 RL4 Vertical Mast Part No. 1266664

Component Damage Hazards

Do not turn the lights on unless the engine is

running. Always turn the lights off before shutting

down the engine.

Do not tow the light tower while the lamps are hot.

Hot lamps will break if moved.

Do not replace lamp bulbs with any bulbs other

than those specified on the machine and in this

manual.

Note: Lamp bulbs contain mercury (Hg). Dispose

of lamp bulbs according to local, state and federal

laws.

Be sure lamp fixture connections are properly

tightened before turning lights on.

Battery Safety

Burn Hazards

Batteries contain acid.

Always wear appropriate

personal protective

equipment, including

gloves, face shield and

long sleeve shirt when

working with batteries.

Avoid spilling or

contacting battery acid.

Neutralize battery acid

spills with baking soda

and water.

Do not use any battery charger greater than 12V to

charge the battery.

Do not remove the vent caps from the battery

when charging.

Do not expose the batteries or the charger to water

or rain during charging.

Explosion Hazards

Keep sparks, flames and lighted

tobacco away from batteries.

Batteries emit explosive gas.

Do not contact the battery terminals

or the cable clamps with tools that

may cause sparks.

Electrocution/Burn Hazards

Avoid contact with electrical terminals.

Inspect the power cord for damage prior to each

use.

Replace any damaged cord before operating.

Do not allow the power cord to become caught or

crushed while raising, lowering or rotating the

mast.

Avoid electrical shock from contact with battery

terminals. Remove all rings, watches and other

jewelry.

Lifting Hazard

Use the appropriate number of people and proper

lifting techniques when lifting batteries.

First Edition • Second Printing Operator's Manual

Work Area Safety

Part No. 1266664 RL4 Vertical Mast 15

Towing Hazards

Read, understand and obey all of your tow vehicle

manufacturer's recommendations, warnings and

instructions before towing this machine.

Do not tow the machine unless the mast is

retracted to the stowed position and is secured.

Do not tow the machine unless rear outriggers and

all jacks have been retracted and stowed.

Do not overload your tow vehicle. Check the

manufacturer's Gross Vehicle Weight Rating

(GVWR). To obtain the gross vehicle weight, add

the tongue weight of the trailer to the vehicle

weight (including vehicle, passengers and cargo).

Do not load cargo on the machine. The light tower

is not designed to carry any extra cargo.

Be sure the hitch is securely attached to the tow

vehicle.

Be sure the safety chains are securely attached to

the tow vehicle. Safety chains should be crossed

below hitch.

Be sure that all driving lights are operational.

Be sure all hitch components, lights and mirrors

and methods of attaching the trailer to the tow

vehicle conform to local, state and federal

regulations.

Do not tow the machine on public roads unless it

meets all governmental regulations for towing.

Do not exceed 60 mph / 97 km/h. Obey all local

and national towing speed laws.

Be sure to chock the wheels when parking on a

hill.

Use extreme care and slow speeds while towing

across uneven terrain, debris, holes or drop-offs.

Note: Do not tow machine when engine is running!

This can cause severe engine/radiator damage

and WILL NOT BE COVERED UNDER

WARRANTY!

Lockout After Each Use

When leaving the machine unattended, secure

from unauthorized use. Unauthorized personnel

may attempt to operate the machine without proper

instruction, creating an unsafe condition.

Operator's Manual First Edition • Second Printing

Legend

16 RL4 Vertical Mast Part No. 1266664

Legend

1 Lamps

2 Winch

3 Control panel (located under access door)

4 Manual storage (located inside cabinet)

5 Leveling jack

6 Kickstand

7 Tie-downs

8 Tongue with trailer hitch

9 T-handle for mast rotation lock

10 Outrigger

11 Forklift pockets

12 Control panel access door

13 Lifting eye

14 Mast

15 GFCI and T-lock receptacle panel

First Edition • Second Printing Operator's Manual

Controls

Part No. 1266664 RL4 Vertical Mast 17

Controls

Control Panel - Standard

1 T-lock receptacle, 240V/30A

2 Light switch

Move the light switch up to turn on the lights.

Move the light switch down to turn off the

lights.

3 Circuit breaker for GFI receptacle

4 Main circuit breaker

Move the main circuit breaker switch up on the

control panel before turning the individual light

switches on or before attempting to use the

convenience receptacles.

Operator's Manual First Edition • Second Printing

Controls

18 RL4 Vertical Mast Part No. 1266664

5 Duplex receptacle with GFI, 120V/20A

Convenience duplex receptacle with Ground

Fault Interrupter (GFI).

6 Hour meter

The hour meter displays the number of hours

the machine has operated.

7 Ignition switch for engine

Turn the ignition switch to the prime position

and hold the engine prime button down to

prime the engine.

Hold the prime button down and turn the

ignition switch to the start position to start the

engine.

Turn the ignition switch to the off position to

turn the engine off.

8 Engine prime button

With the ignition switch in the run position,

press and hold the prime button for

15 seconds before starting the engine.

Release the prime button when the engine

starts.

9 Alternator failure light

Light on indicates that the engine's DC

alternator isn't producing enough voltage.

10 Raise/lower switch (if equipped with electric

winch)

Move the switch up to raise and extend the

mast. Move the switch down to retract and

lower the mast.

Page is loading ...

Terex RL4 User manual

Terex RL4 User manual

Related papers

Other documents